Method of independently controlling motion of movers along a path

ABSTRACT

A system and an apparatus capable of independently driving movers are described herein. The system and apparatus includes: a track that forms a path for movers; a plurality of movers movably mounted on the track for moving along the path; and a plurality of drive elements fixedly arranged along the track. The drive elements each have a surface that is oriented to contact a driven member of the movers. The drive elements are configured to sequentially engage the driven member of a plurality of the movers to provide controlled independent motion of the movers along the track. The drive elements may be driven by rotary motors. A method of independently driving movers is also described herein.

FIELD OF THE INVENTION

A controlled motion system and an apparatus capable of independentlydriving movers are described herein. A method of independently drivingmovers is also described herein.

BACKGROUND OF THE INVENTION

Systems and methods for driving vehicles in various processes arecommercially available and/or disclosed in the patent literature. Suchsystems and methods include: U.S. Pat. Nos. 4,825,111; 5,388,684;6,170,634; 6,536,583; 6,876,107 B2; 6,876,896 B1; 7,134,258; 7,859,139B2; 8,397,896 B2; 8,448,776 B2; 8,678,182; 8,812,152; 8,896,241 B2;9,008,831 B1; 9,126,813; 9,260,210 B2; 9,540,127,B2; 9,590,539,B2; US2012/0097503; US2014/0244028; US 2016/0039061 A1; US 2017/0081135 A1; US2017/0163197 A1; and in the following international patent applications:EP1530541; EP2958834; EP2982472 A1; WO 200064751 A1; WO 200064753 A1;and WO 200064791 A1.

Track systems for transporting vehicles are known. Such track systemsinclude linear synchronous motor (LSM) based systems that facilitatepropulsion of vehicles along the track using electromagnetic force(EMF). Commercially available LSM systems include Rockwell Automation'siTRAK™ intelligent track system; Beckhoff Automation's XTS availablefrom Beckhoff Automation GmbH of Verl, Germany; and, MagneMotion'sMAGNEMOVER® LITE intelligent conveyor system available from MagneMotion,Inc. of Devens, Mass., U.S.A. Although such systems can provide a highdegree of independence of movement of vehicles along their tracks, andcan be used in many different processes, their current performance maybe less than desirable for many high speed converting applications. Forexample, some of such systems are limited to conveying vehicles at amaximum velocity of 2.5-5 meters/second. The magnetic thrust forcegenerated by these systems can also drop off considerably as velocityincreases.

Thus, there is a need for improved apparatuses and methods forindependently driving movers (or vehicles). In particular, there is aneed for apparatuses and methods for independently driving movers athigher speeds and forces that are capable of matching the needs of highspeed converting operations.

SUMMARY OF THE INVENTION

A controlled motion system and an apparatus capable of independentlydriving movers (or vehicles) are described herein. A method ofindependently driving movers is also described herein.

The apparatus, in some cases, may comprise:

a track that forms a path for movers;

a plurality of movers movably mounted on the track for moving along thepath, the movers including a driven member (such as a rack joined to themover) that is oriented to be contacted by at least one drive element(such as a pinion or timing belt) at any position along the path; and

a plurality of drive elements arranged along the track, the driveelements each comprising a surface that is oriented to contact thedriven member (e.g., rack) of the movers, wherein the drive elements areconfigured to sequentially engage the driven member of a plurality ofthe movers to provide controlled motion of the movers independentlyaround the track. The drive elements may each be driven by a rotarymotor.

In some cases, the apparatus may control the motion of independentmovers located in different lanes along a path. In such cases, theapparatus may comprise:

a track that forms a path for movers;

a first lane and a second lane that are parallel to the path;

a first mover movably mounted on the track for moving along the path,the first mover comprising a first driven member that is oriented totravel in the first lane and to be contacted by at least one driveelement at any position along the path;

a second mover movably mounted on the track for moving along the path,the second mover comprises a second driven member that is oriented totravel in the second lane and to be contacted by at least one driveelement at any position along the path;

a first plurality of drive elements arranged along the first lane of thetrack, the drive elements each comprising a surface that is oriented tocontact the first driven member of the first mover, wherein the driveelements are configured to sequentially engage the first driven memberof the movers to provide controlled motion of the first moverindependently around the track, wherein the drive elements are eachdriven by a rotary motor;

a second plurality of drive elements fixedly arranged along the secondlane of the track, the drive elements each comprising a surface that isoriented to contact the second driven member of the second mover,wherein the drive elements are configured to sequentially engage thesecond driven member of the movers to provide controlled motion of thesecond mover independently around the track, wherein the drive elementsare each driven by a rotary motor.

In some cases, the apparatus may provide controlled transport ofarticles along a path. Such an apparatus may comprise:

a track that forms a closed loop path for movers;

a plurality of movers that are configured to transport articles, themovers being movably mounted on the track for moving along the closedloop path, the movers comprising a driven member that is oriented to becontacted by at least one drive element at any position along the path;

a plurality of drive elements arranged along the track, the driveelements each comprising a surface that is oriented to contact thedriven member of the movers, wherein the drive elements are configuredto sequentially engage the driven member of the movers to providecontrolled motion of the movers independently around the track, whereinthe drive elements are each driven by a rotary motor.

The apparatuses described above may further comprise a control system incommunication with the rotary motors for controlling the motion of therotary motors. The control system may comprise a programmable computercontrol system.

A method of independently controlling the velocity profile of moverstraveling along a path is also described herein. In some cases, themethod may comprise the steps of:

-   -   a) providing a system comprising:        -   a track that forms a path for movers;        -   a plurality of movers movably mounted on the track for            moving along the path, the movers comprising a driven member            that is oriented to be contacted by at least one drive            element, wherein the movers comprise at least a first mover            and a second mover; and        -   a plurality of rotationally free drive elements having            rotational axes that are arranged along the track, wherein            the drive elements comprise at least a first drive element            and a second drive element, the drive elements each            comprising a surface that is oriented to contact the driven            member of the movers, wherein the drive elements are            configured to sequentially engage the driven member of a            plurality of the movers to provide controlled motion of the            movers independently around the track, wherein the drive            elements may each be driven by a rotary motor;    -   b) engaging the first mover mechanically with the first drive        element at a first position on the path, wherein the first drive        element is moving with a first rotational velocity, and the        first rotational velocity of the first drive element prescribes        the tangential velocity of the first mover;    -   c) moving the first mover with the first drive element at a        first velocity and first acceleration to a second        position/location on the path; and    -   d) engaging the first mover mechanically with the second drive        element at a second position on the path, wherein the second        drive element is moving with a second rotational velocity, and        the second rotational velocity prescribes the tangential        velocity of the first mover.

A method of independently controlling the velocity profile of moverstraveling along a path. In some cases, the method may comprise the stepsof:

-   -   a) providing a system comprising:        -   a track that forms a path for movers;        -   a plurality of movers movably mounted on the track for            moving along the path, the movers comprising a driven member            that is oriented to be contacted by at least one drive            element at any position along the path, wherein the movers            comprise at least a first mover and a second mover;        -   a plurality of rotationally free drive elements having            rotational axes that are arranged along the track, wherein            the drive elements comprise at least a first drive element            and a second drive element, wherein the second drive element            is positioned downstream in a machine direction from the            first drive element, the drive elements each comprising a            surface that is oriented to contact the driven member of the            movers, wherein the drive elements are configured to            sequentially engage the driven member of the movers to            provide controlled motion of the movers independently around            the track, wherein the drive elements are each driven by a            rotary motor; and        -   a programmable computer control system in communication with            the rotary motors for controlling the motion of the rotary            motors;    -   b) synchronously mechanically engaging the driven member of the        first mover mechanically with the first drive element at a first        position along the path, wherein the first drive element is        driven by a first rotary motor with a first rotational velocity,        and the first rotational velocity of the first drive element        prescribes the tangential velocity of the first mover;    -   c) moving the first mover with the first drive element at a        first velocity profile and first acceleration to a second        position;    -   d) synchronously mechanically engaging the first mover with the        second drive element at a second position, wherein the second        drive element is driven by a second rotary motor with a second        rotational velocity, and the second rotational velocity        prescribes the tangential velocity of the first mover;    -   e) moving a second mover and its driven member into position to        approach and mechanically engage the first drive element,        wherein the driven member of the second mover is moving at a        tangential velocity;    -   f) adjusting the rotational velocity of the first drive element        with the first drive motor to a third rotational velocity, where        the third rotational velocity of the first drive element causes        the tangential velocity of the first drive element to match the        tangential velocity of the approaching driven member of the        second mover; and the mechanical engagement between the first        drive element and the approaching driven member of the second        mover are synchronized; and    -   g) synchronously mechanically engaging the driven member of the        second mover with the first drive element at the first position        wherein the first drive element is driven by the first rotary        motor with the third rotational velocity, and the third        rotational velocity of the first drive element prescribes the        tangential velocity of the second mover; while the tangential        velocity of the first mover is independently controlled by the        second drive element driven by the second rotary motor.

The components of the apparatuses described herein, and the steps of themethods described herein, can be combined in any suitable manner toprovide any number of additional embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic front perspective view of one embodiment ofapparatus capable of independently driving movers (with certain portionsof the apparatus removed).

FIG. 2A is an enlarged, partially fragmented side view of a portion ofthe apparatus of FIG. 1 showing gear racks for joining to the surface ofmovers, and the pinions and toothed belts (only portions of the toothedbelts are shown) that engage with the gear racks.

FIG. 2B is an enlarged, partially fragmented side view of a portion ofthe apparatus, similar to that shown in FIG. 2A, showing a progressionin movement of the movers from right to left.

FIG. 2C is an enlarged, partially fragmented side view of a portion ofthe apparatus, similar to that shown in FIG. 2A, showing a furtherprogression in movement of the movers from right to left.

FIG. 3A is the first of several figures that is an enlarged simplifiedschematic side view of a portion of an apparatus showing three pinionsand at least one rack. This set of figures will show the progression ofmovement of the rack(s) from right to left.

FIG. 3B is an enlarged simplified schematic side view of a portion of anapparatus shown in FIG. 3A which shows a further progression of movementof the rack(s) from right to left.

FIG. 3C is an enlarged simplified schematic side view of a portion of anapparatus shown in FIG. 3A which shows a further progression of movementof the rack(s) from right to left.

FIG. 3D is an enlarged simplified schematic side view of a portion of anapparatus shown in FIG. 3A which shows a further progression of movementof the rack(s) from right to left.

FIG. 3E is an enlarged simplified schematic side view of a portion of anapparatus shown in FIG. 3A which shows a further progression of movementof the rack(s) from right to left.

FIG. 3F is an enlarged simplified schematic side view of a portion of anapparatus shown in FIG. 3A which shows a further progression of movementof the rack(s) from right to left.

FIG. 3G is an enlarged simplified schematic side view of a portion of anapparatus shown in FIG. 3A which shows a further progression of movementof the rack(s) from right to left.

FIG. 3H is an enlarged simplified schematic side view of a portion of anapparatus shown in FIG. 3A which shows a further progression of movementof the rack(s) from right to left.

FIG. 4 is an enlarged fragmented perspective view of the apparatus shownin FIG. 1 that shows one of the toothed belts in greater detail.

FIG. 5 is an enlarged fragmented top perspective view of the apparatusshown in FIG. 1 that shows the gear racks and pinions, and portions ofthe belts, in greater detail.

FIG. 6 is a schematic rear view of the apparatus shown in FIG. 1 thatshows the rotary servo motors that drive the pinions.

FIG. 7 is an enlarged fragmented side view of one of the ends of anapparatus similar to that shown in FIG. 1 in which the curvilinear endsof the track are in the form of a polynomial spline curve.

FIG. 8 is a further simplified side view of one of the ends of anapparatus in which the curvilinear ends of the track are in the form ofa polynomial spline curve.

FIG. 9 is a top perspective view of a variation of the apparatus shownin FIG. 1 that uses movers with gear racks for engaging pinion gears andseparate belt racks for engaging toothed belts.

FIG. 10 is an enlarged perspective view that shows a mover with tworacks.

FIG. 11 is a schematic front perspective view of an alternativeembodiment of an apparatus which is provided with additional drive beltsfor allowing independent motion of the movers around the curved sectionsof the track.

FIG. 12 is a schematic front perspective view of an alternativeembodiment of an apparatus which is provided with a shared rack thatengages a timing belt and a pinion gear.

FIG. 13 is a schematic side view showing an enlarged detail of theinteraction of the timing belt and the rack.

FIG. 14 is a schematic side view showing an enlarged detail of theinteraction of a pinion with a rack.

FIG. 15 is an enlarged perspective view of a mover with a single rackfor sharing between belts and pinions.

FIG. 16A is a schematic perspective view showing one embodiment of aportion of an apparatus having all of its pinions and racks in a singlelane.

FIG. 16B is a schematic perspective view showing a portion of anapparatus having a configuration in which its pinions and racks thatalternate between two lanes.

FIG. 16C is a schematic perspective view showing a portion of anapparatus having a configuration in which its pinions and racks thatalternate between three lanes.

FIG. 16D is a schematic perspective view showing a portion of anapparatus having a configuration in which its pinions and racks thatalternate between four lanes.

FIG. 17A is a perspective view of one embodiment of a track having pathswhich divert/merge.

FIG. 17B is a perspective view of another embodiment of a track havingpaths which divert/merge.

FIG. 18 is a fragmented perspective view of one end of an apparatushaving curved gear racks that are driven by pinion gears for controllingthe motion of movers traveling around the curved section of the track.

FIG. 19 is a perspective view of a portion of an apparatus for turningand re-pitching a component that could be used to manufacture a babydiaper or other disposable products (with various components not shownfor simplicity).

FIG. 20 is a perspective view of a portion of an exemplary discretecomponent assembly application using the independent mover drivetechnology (with various components not shown for simplicity).

FIG. 21 is an enlarged fragmented perspective view of a portion of theapparatus shown in FIG. 20.

FIG. 22 is a further enlarged fragmented perspective view of a portionof the apparatus shown in FIG. 20.

FIG. 23 is a simplified fragmented perspective view that show theapparatus being used to create groups of bottles for a case packingapplication.

FIG. 24 is a perspective view of a portion of an exemplary apparatusused to create dwell time for continuous motion time depended processes(with various components not shown for simplicity).

FIG. 25 is a simplified schematic side view of an exemplary closed pathcontrolled motion system created with a combination of sections drivenby pinion gears and timing belts.

DETAILED DESCRIPTION OF THE INVENTION

A controlled motion system and an apparatus capable of independentlydriving movers are described herein. A method of independently drivingmovers is also described herein.

FIG. 1 shows one non-limiting example of a controlled motion system andapparatus 20. The controlled motion system 20 may serve as a conveyor.The controlled motion system and apparatus 20 comprises: a track 22 thatforms a path P for movers 24; and a plurality of movers (or “vehicles”)24 movably mounted on the track for moving along the path P. The movers24 can be used to transport any suitable type of article (or componentof an article) 10 in a process, such as in a manufacturing process.Articles 10 are shown in the embodiment of the apparatus shown in FIG.23. The movers 24 are joined to a driven feature or member 26 that isoriented to be contacted by at least one drive element 30. A pluralityof drive elements designated generally as 30 are arranged along thetrack 22, and are driven by motors 40.

The system 20 provides for the transport of a plurality of movers 24 atindependent controlled tangential velocities along the path P. The term“tangential velocity” is the measure of velocity in the direction of apath, and is independent of the path curvature. The tangential velocity,thus, applies to a straight line paths as well as curvilinear paths.When it is said that the movers 24 are independently controlled, it ismeant that the spacing and velocities of the different movers 24 can bevaried with respect to each other. The movers 24 are driven by aplurality of drive elements 30 (such as gear pinions 32 and/or timingbelts 36) arranged along the path P that sequentially engage the drivenfeature or member (such as a gear rack or racks) 26 joined to the movers24. (The phrase “joined to” is defined at the end of thisspecification.) The position and velocity of each mover 24 is positivelycontrolled by one or more drive elements 30 (e.g., driving pinion ortiming belt) in control of the rack(s) 26. The rack(s) 26 associatedwith the mover 24 can be passed between adjacent drive elements (such aspinions and/or timing belts) 30—so that at time of transfer, the rack 26is controlled by both leading and trailing drive elements 30.

The term “article”, as used herein with respect to the item beingtransported, includes, but is not limited to a product, a package, alabel, or any portion, component, or partially formed part of any of theforegoing. The term “article” may also include tools, or any other typeof article that it is desirable to transport using the controlled motionsystem. When there are multiple articles, they may be referred to as afirst article, a second article, a third article, etc. The movers 24,the driven members 26, the drive elements 30, and other components ofthe controlled motion system 20 may also be referred to as a first, asecond, a third, etc., when there is more than one of the same.

The track 22 can be in any suitable configuration. The track 22 maydefine a linear path, a curvilinear path, or it may comprise both linearand curvilinear portions. The configuration of the track 22 may form anopen path (that is, a path that has a beginning and an end that are indifferent locations), or a closed path. Non-limiting examples of trackconfigurations include those which define: linear paths, curvilinearpaths, circular paths, elliptical paths, spline paths, curvilinear orspline paths with non-constant radii, race track configured paths, andopen paths or closed loop paths in any other configurations. The term“spline” is used herein in the mathematical sense, and refers to apiecewise polynomial parametric curve constructed so as to approximatelypass through a given set of point parameters. In the embodiment shown inFIG. 1, the track 22 is an endless loop conveyor that is in a race trackconfiguration that comprises both linear portions 22A (along the sidesof the track) and curvilinear portions 22B at the ends of the track. Thetrack 22 may be of any suitable configuration. In some cases, the track22 may be planar. The apparatus will typically consist of two parallelplanar tracks 22 that are symmetric about a central plane between thetwo parallel tracks 22. Typically, this will result in a front track 22Cand a rear track 22D.

As shown in FIG. 6, the track 22 may comprise a frame structure 23 thatcomprises two spaced apart frame members 23A and 23B that are joinedtogether. The frame members comprise a front frame member 23A and a rearframe member 23B. The movers 24 may be located in the space between theframe members 23A and 23B. It is possible for the movers 24 to beconfigured such that some portion or all of the mover 24 is outside theframe members 23A and 23B. Typically, the front track 22C will beattached to or an integral part of front frame member 23A. Typically,the rear track 22D will be attached to or an integral part of rear framemember 23B. One or more lanes for the drive of the movers 24 can bearranged between the frame members 23A and 23B. The term “lanes”, asused herein, refers to several parallel regions inside the track.Typically, the drive components such as the pinions, racks, and belts,for the movers located in each lane will reside in the lanes in whichthe respective movers will travel. These lanes are parallel to the track22.

The apparatus 20 shown in FIG. 1 is described as a front view. In thisembodiment, the path P lies in a vertical plane. The linear portions 22Aof the track 22 are generally horizontally oriented and spaced apart inthe vertical plane. The curvilinear portions 22B are generallyvertically oriented. However, the entire apparatus 20 can be reorientedin any suitable orientation. For example, in another embodiment (asshown in FIG. 19), the apparatus 20 can be “stood on” one of its ends22B so that the linear portions 22A of the track 22 are generallyvertically oriented, and the curvilinear portions 22B are generallyhorizontally oriented. In another embodiment, the apparatus 20 can beoriented so that the path P lies in a horizontal plane. In otherembodiments, the apparatus 20 can be oriented in any orientation betweenhorizontal and vertical.

The movers 24 can be independently driven by the drive elements 30 alongat least a portion of the track 22. When it is said that “the movers maybe driven by the drive elements”, it should be understood that it ismeant that the movers 24 may be directly, or indirectly, driven by thedrive elements 30 (an example of the later situation occurs if themovers 24 are joined to driven members 26, the driven members are drivenby the drive elements 30). The movers 24 may be directly or indirectlydriven by mechanical engagement (such as through the use of meshing gearteeth). Alternatively, the drive may be by friction between the driveelement 30 and the mover 24 (or the driven member 26). For instance, abelt having a smooth outer surface can be used with a driven member 26having a surface configured for frictional engagement with the surfaceof the belt. The term “mechanical engagement”, as used herein, willencompass both interlocking (e.g., meshing teeth) and frictional typesof engagement. Thus, the movers 24 will not be driven by magnetic forces(as in a linear motor). The term “synchronously engaging” may be usedherein to refer to synchronizing the teeth on the drive elements 30 withthe teeth on the driven members 26 at matched registration position andmatched tangential velocity so that the mating teeth engage smoothly,quietly, and with good control. In the case where the drive of thedriven member 26 is by frictional engagement, then “synchronouslyengaging” refers to matched tangential velocity between drive elements30 and drive member 26.

The movers 24 have an outer surface 24A and an inwardly-facing surface(or “inner surface”) 24B. The movers 24 can have any suitableconfiguration. For example, in several of the embodiments shown in thedrawings, the movers 24 may be generally in the configuration of flatplates. The flat plates can be of any suitable configuration including,but not limited to: square, rectangular, and circular. The movers 24 canbe configured to hold articles 10 having a variety of configurations.Alternatively, the outer surface 24A of the movers 24 can be configuredmore precisely correspond to the shape of the portion of the articles 10that faces the movers 24. As shown in FIG. 1, the outer surface 24A ofthe movers 24 can be generally at the same level (or at the same level)as the outermost section of the frame 23 of the track 22. However it ispossible to configure that movers 24 such that the outer surface 24Aextends well outside or inside the envelope of the frame 23.

The apparatus 20 may transport the movers 24 at a constant velocity, avariable velocity, or combinations thereof. The rotation of the movers24 around the track 22 may be continuous, intermittent, or combinationsthereof. The movers 24 may rotate in a clockwise and/or counterclockwise direction, although at any given time, the movers 24 will beonly moving in one of these directions.

The driven features (or “driven members”) 26 may comprise any suitabletype of elements. In some cases, the driven features or driven members26 may comprise portions on the underside of the movers 24 that areconfigured to engage drive elements 30. Alternatively, the drivenmembers 26 may comprise separate components that are joined to themovers 24. The driven members 26 may have an outer surface 26A thatfaces its associated mover 24, and an inwardly-facing surface (or “innersurface”) 26B that faces the drive elements 30. Suitable driven members26 include, but are not limited to the gear rack of a rack and pinionassembly that engages a gear pinion. The driven member 26 may also be arack or toothed member that engages a toothed belt, such as a timingbelt. In another embodiment, the driven member 26 may be a frictionsurface joined to the mover 24 that is in contact with a friction rolleror a friction belt.

The drive elements 30 may comprise any suitable type of components thatare capable of engaging and moving the driven members 26. The driveelements 30 may be positioned in any suitable location relative to thetrack 22. As shown in FIG. 1, the drive elements 30 may be locatedinward of the outermost surface of the frame 23 of the track 22. (Thus,the drive elements 30 may be located inside a track 22 that forms aclosed loop path P.)

Suitable drive elements 30 include, but are not limited to pinion gears,belts, particularly toothed belts (such as toothed timing belts), chainsprockets, chains, or roller pinions. The belts may be in an endlessloop configuration. The drive elements 30 for a given controlled motionsystem 20 can comprise a single type of component, or a combination oftwo or more different types of components. If there are multiple driveelements 30, they may all be similar in type. For example, all of thedrive elements in the controlled motion system 20 may comprise piniongears 32. In another example, all of the drive elements 30 in thecontrolled motion system 20 may comprise belts 36. Belts may provide acost advantage in that they can span a larger portion of the path P thanseveral pinion gears, while only needing a single motor to drive thesame. In other cases, the drive elements may comprise a combination ofdifferent types of components.

In some cases, for example, the drive elements 30 in a given controlledmotion system may comprise a combination of pinion gears 32 and belts36. For example, the belts 36 can be used such as at the ends of thetrack where relative motion between the movers 24 may not be necessary.In the embodiment shown in FIG. 1, there are a pair of toothed belts 36at each of the ends of the track. The drive elements 30 (typically, atleast a portion thereof) may mechanically engage the driven members 26and rotate. The mechanically engaged portion of the drive element 30will drive tangentially to the mover path P. When the drive elements 30are pinion gears 32, they will have a single central axis of rotation.

When the drive elements 30 are belts 36, the belts may have a smooth (ortoothed) inside surface 36A and a (smooth or) toothed outer surface 36B.The belts 36 will be supported by and arranged in a serpentine path torotate around one or more drive sprockets 50. Although only one sprocket50 is shown for each of the belts in FIG. 1, it should be understoodthat each belt 36 will typically be supported by two or more componentssuch as drive sprockets 50 or guide rollers 54 (the latter being shownin FIG. 4). In FIG. 1, the additional sprockets 50 or guide rollers 54will be in locations designated 50A and 50B. The guide rollers 54 areoften non-driven idlers, but could alternatively be driven. The guiderollers 54 may have teeth to mate with any teeth on the inside surface36A of the timing belt or they can have a smooth surface with no teeth.The inside surface 36A of the belts 36 may be supported in any suitablemanner, such as by a plurality of rollers or by one or more curvedbacking plates or guide rails. For shorter belt spans, curved backingplates are suitable. For the longer spans, such as 180 degree beltspans, the friction associated with using a backing plate may beimpractical, and backup rollers may be more suitable. The backup rollersalong the inner surface of the belts in FIG. 1 are not shown forsimplicity. FIG. 4 shows the backup rollers 60. In other embodiments,such as shown in FIG. 11, the apparatus 20 may have parallel timing beltdrives for straight sections of the track 22 as alternative to in-linepinion gears 32. Such parallel timing belts may transfer the racks 26 totiming belt(s) that follow the curve.

When it is said that the drive elements 30 are “fixedly arranged” alongthe track, it is meant that the position of the axes of rotation of thedrive elements 30 is fixed. It is understood that pinion gears 32 willrotate around their axes. The belts 36 are driven by sprockets 50 whichare mounted on a shaft 52 with a fixed axis. The belts 36 are movablesuch that, at any given time, portions of the belt 36 will move alongthe path P. At any given time, other portions of the belts 36 will bemoving around one or more sprockets 50 that impart motion to the belt 36by virtue of being driven by a motor 40. Thus, the drive elements 30(such as the pinion gears 32 and belts 36) are free to rotate (or“rotationally free”). Such an arrangement is distinguishable fromself-powered vehicles that have motors that are incorporated into thevehicles that move along a path.

The drive elements 30 are each driven by motors such as rotary motors40, so that there are a plurality of rotary motors 40. The term “rotarymotors” includes, but is not limited to, electric motors and hydraulicmotors. The rotary motors 40 can also be rotary servo motors. Thus, thecontrolled motion system 20 may be free of linear motors, such as linearsynchronous motors that drive vehicles around a track by electromagneticforce. The rotary motors 40 can be in any suitable location relative tothe track 22. As shown in FIGS. 1 and 6, some or all of the rotarymotors 40 may be at least partially located outboard of the rear framemember 23B. The term “outboard”, as used herein, means in a directionthat is positioned away from the space between the frame members 23A and23B in which the movers 24 are located.

Each drive element 30 may be driven by a rotary servo motor 40 with amotion profile. The drive elements 30 can be directly coupled to therotary motors 40 such that any rotational displacement of the rotarymotor 40 will result in an equal rotational displacement of theconnected drive element 30. The drive elements 30 can be connected tothe rotary motors 40 with any number of mechanical power transmissionmeans known to one skilled in the art. Power transmission means couldinclude planetary gear reducers, worm gear reducers, gear boxes, beltdrives, chain drives, roller pinion drives, hydraulic transmissions,etc. The power transmission coupling between the drive element 30 andmotor 40 may include a mechanical gear ratio n, such that a rotationaldisplacement of the motor theta (θ) will result in a rotationaldisplacement of drive element 30 of 1/n*theta. Correspondingly, theangular velocity and acceleration of the drive element 30 will be 1/n ofthe angular velocity and acceleration of the rotary motor 40 while thetorque applied to drive element 30 will be a product of n multiplied bythe rotary motor 40 torque. Alternatively, the drive rotary motor 40 canbe integral with the drive element 30. The motion profiles of theplurality of rotary servo motors 40 may be synchronized by a controlsystem 46. The control system 46 can comprise a programmable computercontrol system.

In this system, the velocity profile of each mover 24 traveling alongthe path P can be controlled by synchronized cooperation with aplurality of drive elements 30 distributed along the paths P such thatthe velocity profile of the individual movers 24 are independentlycontrolled. The term “velocity profile” is used herein in its ordinarysense in the field of motion control engineering. Thus, the velocityprofile refers to the tangential velocity of a mover at various timesand prescribed positions along a path. The velocity profile may, thus,comprise a prescribed motion plan that controls the position, velocity,acceleration, and jerk of the mover as it travels along a path and astime transpires. The velocity profile of the individual movers 24 iscontrolled by the commanded rotational velocity profile of the rotarymotor 40 which drives the movers 24 through the mechanical drive train.The mechanical drive train includes the mechanical power transmissionsuch as a coupling or gear reducer linking the rotary motor 40 and driveelement 30 and rotary motion to tangential motion achieved between thepinion gear 32 and rack 26 or drive sprocket 50, timing belt 36, andtiming belt rack 26. The position of the mover 24 along the path P canbe tracked virtually in the control system or measured by means of ahoming position sensor such as a camera, radar, linear encoder, an arrayof Hall effect sensors, linear array of position switches, or otherlinear displacement sensors. The position of each mover 24 along thepath P (the “initial homing position” of the movers) can be initiallymeasured at a home position by using a homing routine that moves eachmover 24 by a homing position sensor. The initial homing position ofeach mover 24 can also be set by a mechanical set up fixture. When atthe home position, the relative path position and corresponding positionin a rotary feedback sensor such as an encoder or resolver internal tothe rotary motor can be recorded by the programmable computer controlsystem. After homing, the position of each mover 24 can be calculated bythe programmable computer control system and tracked virtually based onmovement of each rotary motor 40 that is mechanically coupled to themovers 24. With multiple free-spinning drive elements 30—both pinions 32and drive sprockets 50, it is necessary to establish relative homingpositions of any drive element 30 not engaged with movers 24 during theinitial homing. One strategy is to reposition the movers 24 to newpositions where they engage with different drive elements 30 and measurethe new home positions. This is repeated until relative positions of alldrive elements 30 have been established. It is also possible to installrotational homing sensors on all drive elements 30. These will establishthe relative home between all drive elements 30 and the movers 24 oncethe relationship between drive elements 30 engaged with movers 24 isestablished. Another simple homing procedure is to complete homing witha mechanical fixture such as a long gear rack that can expand across alldrive elements 30 and lock all drive elements in phase.

Torque applied by the rotary motor 40 is converted into a thrust forceacting on the mover 24 tangential to the path P by the rotary motion totangential motion achieved between the pinion gear 32 and rack 26 ordrive sprocket 50, timing belt 36, and timing belt rack 26. The motionprofile of the mover 24 traveling along the path P can be controlled toprovide a desired tangential force at the mover 24. This tangentialforce can be used to accelerate the mass of the mover 24 and a payload.This tangential force can be used to apply thrust from the mover 24 toan external element such as process tooling. Tangential force availablein a region along the track 22 at mover 24 can be increased by additionof a rotary motor 40 capable of more torque or changes to the finaldrive ratio of the mechanical drive train. The tangential force at themover 24 can also be increased by contacting rack 26 by more than onedrive element 30 and more than one rotary motor 40. Hence it is possibleto locally tailor the force available along the path P of track 22. Thiscan allow use of lower cost rotary motors 40 with lower available torquewhere high tangential forces are not needed.

More specifically, a first mover 24-1 is mechanically engaged by a firstdrive element 30-1 so that the rotational velocity of the first driveelement 30-1 prescribes the tangential velocity of the first mover 24-1.Any changes to the rotational position, velocity, and acceleration ofthe first drive element 30-1 result in proportional changes intangential position, velocity, and acceleration of the first mover 24-1.

As the first mover 24-1 travels, it encounters and is mechanicallyengaged by a second drive element 30-2 with a rotary velocity andposition synchronized at equal tangential velocity as the first driveelement 30-1 and with the drive element 30-1 gear teeth synchronizedwith rack 26-1 teeth. The movement and velocity of the first mover 24-1is controlled by the synchronized rotational position, velocity, andacceleration of combined first and second drive elements 30-1 and 30-2.

As the first mover 24-1 travels, the first drive element 30-1 disengagesthe first mover 24-1. The first mover 24-1 will then only be controlledby the second drive element 30-2. The rotational velocity and phase ofthe first drive element 30-1 is adjusted to match tangential velocityand phase of rack teeth of the second mover 24-2.

FIGS. 2A-2C are close-up views of a portion of the apparatus 20 thatshow, among other things, the gear racks 26 that will be joined to theinner surface of movers 24 (the movers are not shown for simplicity).These figures also show the pinions 32 and toothed belts 36 (onlyportions of the belts are shown) that engage with the gear racks 26. Theracks 26, as noted above, have a first or outer surface 26A, and asecond or inner surface 26B. The inner surface 26B of the racks 26 havea plurality of teeth 28 thereon. These teeth 28 may engage with theteeth 34 on the surface of the pinion gears 32. The belts 36 have afirst or inner surface 36A, and a second or outer surface 36B. The outersurface 36B of the belts 36 have a plurality of teeth 38 thereon. Theseteeth 38 may engage with the teeth 28 on the inner surface 26B of theracks 26. FIGS. 2A-2C show a progression of movement of three racks,26-1, 26-2, and 26-3, from right to left in the machine direction (MD).As shown in FIGS. 2A-2C, each pinion 32 will only contact one rack 26 atany time. If the pinion 32 contacted two racks 26 they would not be ableto have relative motion therebetween. The racks 26 will typicallycontact either one pinion 32 or toothed belt 26, but during transfers,the racks 26 can contact two drive elements 30, which may be pinions 32and/or toothed belts 36.

FIG. 4 shows two of the toothed belts 36-1 and 36-2 in greater detail.As shown in FIG. 4, portions of inside surfaces of the belts will wraparound a plurality of guide rollers 60, which support the belts. Thebelts 36-1 and 36-2 are supported parallel to the path P to ensureengagement of the belt teeth 38 and teeth 28 on the rack 26 associatedwith the mover 24 to enable tangential driving of the movers 24 withoutjumping and/or disengagement of the teeth. As shown in FIG. 4, all ofthe teeth 28 on the racks 26 do not have to be in engagement with theteeth 38 on the toothed belts 36-1 and 36-2. For instance, as the racks26 travel around the curved portion 22B of the track, the toothedportions at the ends of the racks 26 may not be engaged with the teethon the belts due to the flat, plate-like configuration of the racks (andthe curved configuration of the adjacent portion of the belts). It isonly necessary that some of the teeth are in engagement.

FIG. 5 shows an embodiment of the gear racks 26 and pinions 32 ingreater detail where the movers 24 are moved along parallel paths P1 andP2 with parallel systems of drive elements 30. The components of theapparatus 20 shown in FIG. 5 will be designated by reference numbersthat specify the path in which the component is located as a prefix, anda hyphen followed by similar reference numbers used previously withrespect to each component. For example, FIG. 5 shows the movement ofracks, P1-26-1, P1-26-2, and P1-26-3 generally referred to as P1-26 andP2-26-1, P2-26-2, and P2-26-3 generally referred to as P2-26,respectively (and associated movers P1-246-1, P1-24-2, and P1-24-3generally referred to as P1-24 and P2-24-1, P2-24-2, and P2-24 generallyreferred to as P2-24-3) in an arrangement where the movers P1-24 andP2-24 are moved along parallel paths P1 and P2 with parallel systems ofdrive elements P1-30- and P2-30. As shown in FIG. 5 in path P1, eachpinion P1-32 will only contact one rack P1-26 (and associated moverP1-24) at any time. If the pinion P1-32 contacted two racks (and moversP1-24), the different racks P1-26 would not be able to have relativemotion. The racks P1-26, on the other hand, will typically contacteither one drive element P1-30, and during transfers, two drive elementsP1-30 (e.g., pinions and/or belts). Likewise in path P2, each pinionP2-32 will only contact one rack P2-26 (and associated mover P2-24) atany time. If the pinion P2-32 contacted two racks (and movers P2-24),the different racks P2-26 would not be able to have relative motion. Theracks P2-26, on the other hand, will always contact either one driveelement P2-30, and during transfers, two drive elements P2-30 (e.g.,pinions and/or belts). Racks P1-26 from path P1 will not engage withpinions P2-32 from path P2. And likewise, racks P2-26 from path P2 willnot engage with pinions P1-32 from path P1. The motion of racks P1-26are independent of racks P2-26. It is possible for a rack P1-26 frompath P1 and a rack P2-26 from path P2 to overlap during their motion.The term “overlap”, as used herein, means that the racks 26 haveportions that are coextensive in the machine direction along the path.It does not require that one rack overlie a portion of another rack.This makes it possible for a mover P1-24 to move in close proximity withor come in contact with an adjacent mover P2-24. Movers are shown toalternate sequence between paths P1 and P2. For example movers are shownin machine direction sequence from left to right starting with P2-24-1,then P1-24-1, P2-24-2, P1-24-2, P2-24-3, and finally P1-24-3. It ispossible to configure the system in any desired order of sequences suchas P1-24-1, P1-24-2, P2-24-1, P2-24-2, P1-24-3, and P2-24-3 or P1-24-1,P1-24-2, P12-24-3, P2-24-1, P2-24-2, and P2-24-3. It is also possible toconfigure the movers P1-24 to follow path P1 only and engage with only asingle lane of drive elements P1-30. The drive system can also beconfigured to include any number of parallel paths P1, P2, P3, P4, P5,P6, ore more and movers P1-24, P2-24, P3, 24, P4-24, P5-24, P6-24, ormore.

FIG. 6 shows the rotary servo motors 40 that drive the pinions 32 (shownin FIG. 5) and toothed belts 36-1 and 36-2. In this particularembodiment, there are a plurality of rotary servo motors 40A that arelocated along the linear portions 22A (along the sides of the track)that drive the pinions 32. There are also two rotary servo motors 40Bthat are located inward of the ends 22B of the track, each of whichdrives one of the belts along the curvilinear portions 22B at the endsof the track.

Numerous alternative embodiments are possible.

FIGS. 7 and 8 show that in certain cases, the ends 22B of a race trackconfigured track 22 may be in the form of a polynomial spline curve,such as a fifth order polynomial spline curve. This provides a smoothertransition (in transition portions or “transitions”) between the linearsections 22A of the track and the curved sections 22B of the track atthe ends of the track. This greatly reduces the stresses due toacceleration and jerk on the movers 24 as they travel into, around, andout of the curved sections of the track at the ends 22B of the track. Asshown in FIG. 7, the portion of the belt 36 along the polynomial splinecurve can be supported by a plurality of closely-spaced rollers 60 thatmay, but preferably do not, contact each other. The placement of rollers60 ensures that the belt 36 will follow the prescribed spline path ofthe track and movers 24.

FIG. 8 shows a simplified alternative view of the ends 22B of a racetrack configured track 22 shown in FIG. 7. Components have been removedfor clarity to show only the track 22 and the support rollers 62 thatwould be part of movers 24 as they travel around the track 22. A shortfragmented portion of a belt 36 is shown. The end 22B track 22 in FIG.8, follows a fifth order polynomial spline curve and the linear sections22A follow a straight line. As shown in FIG. 8, at least a portion ofthe back 36A of the belt 36 can be supported by one or more stationarycurvilinear backing plates 58. The backing plates 58 can employ lowfriction materials such as ultra-high molecular weight polyethylene orTEFLON® synthetic resin. The backing plates 58 can also use compressedair to flowing through small orifices to float the belt across thebacking plate 58.

FIG. 9 shows an embodiment of an apparatus 20 which uses movers 24 thathave both gear racks for engaging pinion gears 32 and separate beltracks for engaging timing belts 36. This allows use of off-the-shelfcommercial racks such as racks for CP20 gears and AT20 timing belts. InFIG. 9, the timing belt 36 is in a central lane with pinion gears 32 oneither side. While two lanes of pinion gears 32 are shown, other numbersof pinion lanes can be used such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, etc.

FIG. 10 shows a mover 24 with two racks (that can be used in theembodiment shown in FIG. 9) in greater detail. The timing belt rack 126Ais in the center and the gear rack 126B is closer to the support rollers62. The bearing system for this embodiment uses four sets of horizontalrollers 62A to 62B to support the mover 24 in the track 22. Larger innerrollers 62A will engage the outer track surface to carry the centrifugalforces and the smaller inner rollers 62B will engage an inner tracksurface. Four vertical rollers 64 are used to position the mover in thecross machine direction and carry moments in the horizontal plane. Anyof the rollers can be adjusted using an eccentric to adjust clearance orpreload with the track.

FIG. 11 shows an alternative embodiment of an apparatus 20 which isprovided with multiple drive belts, 36-1, 36-2, 36-3, and 36-4, forcontrolling the motion profile of movers 24 traveling around a curvedsection 22B of track 22 and allowing independent relative motion of themovers 24 around the curved sections 22B of the track 22. In thisembodiment, dual lanes of interleaving drive belts are used to drive acommon belt rack 26 connected to a mover 24. Referring to FIG. 11, thetwo adjacent parallel groups of belts 36-1 and 36-2 nearest the camtrack plate 68 can be engaged with the mover (upper right hand mover)24-1. In the embodiment illustrated, a total of four independent belts36-1, 36-2, 36-3, and 36-4 are used to transport the mover 24 around acurved section of track. These belts are configured to follow thecurvature of the mover path P and can be supported by a plurality ofrollers, backing plates, or a combination of backing plates and rollers.Each of these drive belts 36-1, 36-2, 36-3, and 36-4 can be driven by anindependent servo motor. A combination of multiple discrete belts canalso be driven by a single servo axis. When the mover belt rack isengaged by only one drive belt, the belt drive axis can be acceleratedto create relative motion between the mover 24 and any other nearbymovers 24 traveling along the path. Motion of interleaved adjacent drivebelts can be synchronized so that the mover belt rack smoothlytransitions between the belts. Driving a mover 24 around a curved pathat a constant belt tangential velocity can require high amounts ofdriving force and energy. This is due to the center of mass of the mover24 accelerating due to the increased path length for curved regions at ahigher radius of curvature outside the belt path. Multiple independentcontrol regions by multiple belts around the curved path make is easierto adjust the tangential velocity of each mover 24 as it travels aroundthe curved path. This can enable keeping a constant or nearly constanttangential velocity for the center of mass of the mover which reducesacceleration and required driving force. Any practical number of drivebelts can be employed, and in some embodiments it may be beneficial tohave combinations of three, four, or more belts in selective engagementwith a mover rack. Likewise, it might be beneficial to configure thebelts to have 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, or more independentbelts to drive the mover through a track curve. Independent belt drivesegments can also be configured to follow a straight sections of track.Multiple belts in straight track sections can be interleaved to enablerelative mover between adjacent movers using the same principle as therack and pinion gearing. Motion of a mover around a complete tracksystem can be controlled by engagement by a plurality of timing beltswith no gear racks in use. The motion of a mover around a track systemcan also be accomplished by any combination of gear racks and discretesegments of toothed (e.g., timing) belts that engage with and follow thepath of a mover 24. Belt racks for adjacent movers can alternate betweentwo or more lanes. FIG. 11 shows an embodiment with racks in twoparallel lanes. The outer two adjacent parallel groups of belts farthestfrom the cam track plate, 36-3 and 36-4, engage with movers in a secondlane. Movers in the first and second lane are under the control ofdifferent drive motors and are continuously able to have prescribedrelative motion.

FIG. 12 shows an alternative embodiment of an apparatus 20 which isprovided with movers 24 with a shared rack 26 that engages both a timingbelt (such as belt 36-1 or belt 36-2) and pinion gears 32. FIG. 13 showsan enlarged detailed view of the interaction of the timing belt 36 withthe rack 26. The rack teeth 28 can be cut to fit with a standard timingbelt tooth profile such as BRECOFLEX AT10™ polyurethane timing beltavailable from BRECOflex Co., LLC of Eatontown, N.J., U.S.A. FIG. 14shows an enlarged detailed view of the interaction of the pinion 32 withthe rack 26. The rack gear teeth 34 can be cut to fit with the toothprofile in the rack 26. FIG. 12 illustrates that sharing the rackbetween the timing belt (such as belt 36-1 or belt 36-2) and pinions 32can result in a reduced width for the system due to no need fordedicated lanes for both belt and gear racks. FIG. 15 shows the narrowersimplified mover 24 with a single rack 26 for sharing between belts andpinions. The bearing system uses four sets of V-rollers to positions themover with the track. Larger inner V-rollers will engage an outer tracksmaller inner V-rollers will engage an inner track.

FIGS. 3A through 3H show an example of a linear sequence of racks andpinions in a single lane. These figures show a simplified series ofthree pinions, 32-1, 32-2, and 32-3 and one or two racks, 26-1 and 26-2.The racks 26-1 and 26-2 are traveling (that is, they are being moved ina machine direction, MD) from right to left. For illustrative purposesfor FIGS. 3A through 3H, the racks 26-1 and 26-2 will enter from theright at velocity V1 and exit to the left at velocity V3. The racks aredecelerated such that exit velocity V3 (shown in FIG. 3G) is less thanentrance velocity V1. The spacing, S1, S2, and S3, measured along thepath between periodic racks is subsequently decreased from the entranceto the exit. Referring to FIG. 3A, at the entrance to the right, thevelocity of rack 26-1 is controlled at constant velocity V1 by the firstpinion 32-1 rotating at constant rotational velocity oil. Rack 26-1moves at constant velocity V1 from right to left and rack 26-1approaches the second pinion 32-2 as shown in FIG. 3B. Prior totransfer, the rotational velocity of the second pinion 32-2 is adjustedto equal the rotational velocity of the first pinion 32-1. Also prior totransfer, the position of the gear teeth 34-2 for the second pinion 32-2are rotated so their position is synchronized to mesh with the gearteeth 28-1 of rack 26-1. In FIG. 3C, as rack 26-1 travels to the left,rack 26-1 is transferred at constant velocity V1 to the second pinion32-2 with mesh of gear teeth synchronized. During the time of transfer,the first pinion 32-1 and the second pinion 32-2 are both rotating atconstant rotational velocity oil. There is preferably some overlap timewhere rack 26-1 is engaged by both the first pinion 32-1 and the secondpinion 32-2. As rack 26-1 continues to travel from right to left, therack 26-1 will no longer be engaged by the first pinion 32-1.

In FIG. 3D, when rack 26-1 is engaged by the second pinion 32-2 alone,it is now possible to decelerate rack 26-1 to velocity V3. Therotational velocity of the second pinion 32-2 is decelerated. As rack26-1 approaches the third pinion 32-3, it is moving at constant velocityV3. Prior to transfer, the position of the gear teeth rack 26-1 issynchronized to mesh with the gear teeth 28-3 of the third pinion 32-3.In FIG. 3E, after transfer of rack 26-1 to the third pinion 32-3, therack 26-1 is moving at constant velocity V3 and the second pinion 32-2and the third pinion 32-3 are both at matched rotational velocity. Thereis preferably some overlap time where rack 26-1 is engaged by both thesecond pinion 32-2 and the third pinion 32-3. As rack 26-1 continues totravel to the left, rack 26-1 disengages from the second pinion 32-2 andit is possible to adjust rotational velocity and gear tooth position forthe second pinion 32-2.

In FIG. 3F, while rack 26-1 is traveling at velocity V3 and engaged bythe third pinion 32-3, the second rack 26-2 engaged with the firstpinion 32-1 is traveling at velocity V1 which is a higher velocity thanV3. As rack 26-1 disengages from the second pinion 32-2, the pinion 32-2must be at tangential velocity V3. Before second rack 26-2 can engagewith the second pinion 32-2, the rotational velocity of the secondpinion 32-2 must be accelerated to tangential velocity V1. Referring toFIG. 3G, prior to transfer of the second rack 26-2 from the first pinion32-1 to the second pinion 32-2, the rotational velocity of the secondpinion 32-2 is adjusted to equal the rotational velocity of the firstpinion 32-1. Also prior to transfer, the position of the gear teeth forthe second pinion 32-2 are rotated so their position is synchronized tomesh with the gear teeth of the second rack 26-2. It will take some timeto adjust the velocity of the second pinion 32-2. The time required toadjust rotational velocity and synchronization can be minimized bymaximizing motor torque and minimizing rotational inertial and friction.In a practical system running at high velocity, the control system mayalso require some additional computational time beyond time dictated byphysics. Because of the need to adjust the rotational velocity andposition of the second pinion 32-2, it is necessary for there to be somespace between the trailing end of the first rack 26-1 and the leadingend of the second rack 26-2. Hence, it would not be possible for theends of the first rack 26-1 and the second rack 26-2 to be adjacent andtouching within a single lane. The first rack 26-1 and the second rack26-2 must maintain a minimum spacing between racks dictated by theperformance of the second pinion 32-2 rotating mechatronic system. InFIG. 3H, the second rack 26-2 is engaged by the pinion 32-2 alone, it isnow possible to decelerate the second rack 26-2 to velocity V3. Therotational velocity of the second pinion 32-2 is decelerated. The firstrack 26-1 continues to travel at velocity V3 and is controlled byengagement with the third pinion 32-3. Note that the distance and pitchbetween the first rack 26-1 and the second rack 26-2, S3, has decreasedfrom FIG. 3F to FIG. 3H.

In other embodiments, the distance between the first rack 26-1 and thesecond rack 26-2 can be increased along any portion of the path P byadjusting the velocities of the pinions 32 in an opposite manner

The mover 24 and the attached rack 26 may have any suitable machinedirection lengths which (as shown in FIG. 4) are designated LM and LR,respectively. The machine direction length, LM, of the mover 24 can bethe same as machine direction length, LR, of the attached rack 26. Tomaintain control of the mover 24 during transfer from sequential driveelements 30, the machine direction length, LR of the rack 26 must begreater than or equal to the minimum machine direction spacing betweensequential drive elements 30. It is beneficial for the machine directionlength, LR of the rack 26 to be greater than the length of the minimummachine direction spacing between sequential drive elements 30, toprovide some overlap where both sequential drive elements are engagewith the rack 26 during transfer. In this case, if the racks for twosequential movers travel in a single lane, it will be necessary tomaintain a minimum gap between the movers 24 equal to the minimum gaprequired by sequential racks 26 in a single lane. Alternatively, themachine direction length LM of the mover 24 can be longer than themachine direction length, LR, of attached rack. In this case, if thedifference in length of the mover 24 minus rack length exceeds theminimum distance required between racks 26 traveling in a single lane,it is possible to position movers very close to each other or eventouching. Alternatively, the machine direction length LM of the mover 24can be shorter than machine direction length, LR, of the attached rack26. In this case, the minimum gap that can be achieved betweensequential movers 24 is equal to the minimum gap between sequentialracks 26 plus the difference in length between rack and mover.

It can be beneficial for the length LR of the rack 26 to exceed themachine direction length LM of the mover 24. This can reduce the totalnumber of drive pinions 32 and drive motors 40 required to drive themovers 24 along a given path. This also enables movers 24 with verysmall MD lengths. Lengths as small as 40 mm or even 20 mm could bepossible.

For some processes it might be desirable to plan the motion ofsequential movers such that two or more movers are in close proximity oradjacent. Such would be the case if picking up a continuous stream ofproducts queued at close spacing and then spacing them out to a largerpitch.

FIGS. 16A-16D are simplified schematic perspective views showing variousembodiments of varying counts of parallel rack and pinion lanesfollowing parallel paths P1, P2, P3, and P4. The teeth on the racks 26and pinions 32 are not shown for simplicity. FIG. 16A shows anembodiment with all pinions 32 and racks 26 in a single plane which arein a single lane, L1. FIG. 16B shows an embodiment where pinions 32 andracks 26 alternate between two lanes, L1 and L2. FIG. 16C shows anembodiment where pinions 32 and racks 26 alternate between three lanes,L1, L2, and L3. FIG. 16D shows an embodiment where pinions 32 and racks26 alternate between four lanes, L1, L2, L3, and L4. Although, thedirection of movement (machine direction, MD) is shown from right toleft in these figures, the MD can be from left to right in alternativeembodiments.

The parallel pinion lanes enable close proximity of adjacent movers 24.The parallel pinion lanes provide time to adjust the velocity/timing ofthe pinions 32 for the next rack 26. As described in greater detailbelow, the number of adjacent movers 24 is equal to the number ofparallel lanes. Such embodiments enable very small pitches includingless than or equal to about 40 mm

FIG. 16B shows an embodiment where pinions 32 and racks 26 alternatebetween two parallel lanes, L1 and L2. In the configuration illustrated,the machine direction length LR of the rack 26s is longer than themachine direction length LM of the attached movers 24. In this dual laneconfiguration, it is possible for the racks 26 in each of the twoparallel lanes L1 and L2 to overlap each other. The dual lane driveconfiguration makes it possible to position to sequential movers 24 invery close proximity with each other, touching, or even interfering withor passing each other. In this configuration, it will not be possible tobring a third mover in sequence in close proximity of adjacent to theother two movers. This would require two racks 26 in the same lane toapproach very close to each other and would not provide room for speedchange of pinions 32 when disengaged from racks.

FIG. 16C shows an embodiment where pinions 32 and racks 26 alternatebetween three lanes L1, L2, and L3, and the racks 26 are longer than theattached movers 24 (LR is greater than LM). In this configuration, it ispossible for racks 26 in the three parallel lanes L1, L2, and L3 tooverlap each other and for two or three movers 24 in sequence to be inclose proximity with each other.

FIG. 16D shows an embodiment where pinions 32 and racks 26 alternatebetween four lanes L1, L2, L3, and L4, and the racks 26 are longer thanthe attached movers 24 (LR is greater than LM). In this configuration,it is possible for racks 26 in the four parallel lanes L1, L2, L3, andL4 to overlap each other and for three or four movers 24 in sequence tobe in close proximity with each other.

FIGS. 17A and 17B show still other embodiments. FIG. 17A is aperspective view of one embodiment of a track 22 having multiple paths,P1 and P2, onto which the movers 24 can be diverted. When the pivotingtrack gate 70 is rotated up, the movers 24 will follow a closed ovoidprimary path P around the closed ovoid track. When the pivoting trackgate 70 is rotated down, a diverting path is opened from the ovoid trackto the straight track below. Movers 24 rotating counter clockwise alongthe ovoid track can leave the ovoid track through the track gate 70 andare fed into the straight section 72A or 72B of track below. This canprovide a convenient means for storing movers 24, for instance to changemover tooling or the number of movers on the track 22. Likewise, movers24 in the straight section 72A or 72B of track can move from thestraight section 72A or 72B of track and up the track gate 70 to theovoid track. Multiple straight sections 72A and 72B of track and enablestorage of different sets of movers 24 with differentiated tooling (thatis, different features or configurations for holding articles) thatmight be used for making different sizes or types of products. Thestraight section connected to the track gate 70 can be selected byindexing the straight track sections in the direction orthogonal to theovoid mover track 22 (as shown by the double-headed arrow). In additionto storage and retrieval from straight track sections 72A or 72B, apivoting track gate 70 can be used to divert movers 24 between multipletracks and could be used to create a network of alternative trackroutes.

FIG. 17B is an alternative embodiment of a track 22 having multiplepaths, P1 and P2, onto which the movers 24 can be diverted. The trackshown in FIG. 17B can be thought of as having a “side shift” feature.The parallel diverting tracks can be indexed orthogonally to mover pathP to align a filler track segment 76A or 76B that will close thecontinuous path of the ovoid track 22. Indexing a diverting trackin-line with the ovoid path will open the ovoid path and allow movers todivert between the ovoid path and the diverting track. This can allowdiverting between the ovoid path and multiple diverting tracks. Thediverting tracks can be used for storage of movers 24 with differenttooling.

FIG. 18 illustrates an alternative embodiment for controlling the motionprofile of movers 24 traveling around a curved section 22B of track andallowing independent relative motion of the movers 24 around the curvedsections 22B of the track 22. Instead of multiple timing belts as inFIG. 11, the movers 24 are driven by stationary pinion gears 32 engagingwith curved gear racks 26. The path of the gearing for each of thecurved gear racks 26 is cut such that the rack 26 will remain engagedwith the pinion gear 32 as the mover 24 travels along the curved path ofthe cam track. In the illustrated embodiment, there are a total of sixunique rack shapes 226-1, 226-2, 226-3, 226-4, 226-5, and 226-6 that arearranged in six parallel lanes and attached to each mover 24. The drivepinions 32 connected to independent motors 40 around the track are alsoarranged in one of the six lanes corresponding to the six racks. Rack226-3 is straight and can be driven by pinions 32-3 in straight sectionsof track 22. Rack 226-1 is curved at a constant radius and is driven bypinions 226-1 through the constant radius section of the track 22. Thegearing for racks 226-2, 226-4, 226-5, and 226-6 follow engineeredcurves that allow pinion gears 32 in corresponding lanes to drivethrough the transition segments of the track that follow a polynomialspline. Racks 226-4 and 226-5 are shaped to maintain engagement withpinions 32-4 and 32-5 as the mover transitions between a straightsection 22A of track to the spline curve section 22B.

Racks 226-2 and 226-6 are shaped to maintain engagement with pinions32-2 and 32-6 as the mover transitions between a spline curve sectionand a constant radius curve section of track. Some racks such as thestraight and constant radius racks may be driven by multiple pinions insequence. Some racks may only be driven by a single pinion until controlof the mover is transitioned to pinions in another lane. The group ofracks are transferred from pinion to pinion in sequence as the movertravels around the path of the track. The rotational position of eachpinion gear is synchronized with the mating rack to enable a smooth andcontrolled transfer. Controlling the mover 24 by engagement ofindividual pinions 32 around the track 22 enables control of the motionprofile of the mover 24 anywhere along the track 22 including the curvedregions 22B. This can allow relative motion between adjacent movers 24in the curved regions 22B. This can also allow adjusting the velocityalong the track path P to maintain a constant tangential velocity of themover 24 center of mass which greatly reduces the driving forcerequired.

FIGS. 19-25 illustrate some examples of the many useful applications forthe high performance independent mover drive technology describedherein. The examples generally involve controlled transport of articles10 carried by movers 24 along a path P and the controlled motion ofdiscrete tooling 112 and 114 carried by movers 24 along a path P.

FIG. 19 illustrates an application for turning and re-pitching acomponent of an article 10. The apparatus 20 shown in FIG. 19 could, forexample, be used to manufacture a baby diaper or other disposableproducts. An alternative turn and repitch embodiment to carry out thistype of process is described in U.S. Pat. No. 8,720,666 which employscam driven heads to acquire, adjust the pitch, rotate, and transfer acomponent of a baby diaper. In FIG. 19, the track structure has beenomitted for simplicity. Referring to FIG. 19, a diaper chassis 10 entersfrom the right side and is transferred at matched speed to a vacuum head80 and is held on by vacuum. The vacuum head 80 is rotatably affixed toa mover 24. The vacuum head 80 is moving in the upward direction at aconstant velocity in the figure. Vacuum applied through holes in thevacuum head 80 allows the article 10 to be securely held against thesurface of the head selectively when the vacuum is applied. Note thatthe tangential matched speed transfer from the vacuum anvil roll 82 tothe flat vacuum head 80 is very well controlled due to the naturaltangential nature of the linear motion of the head 80 and mover 24 witha rotating cylindrical anvil roll 82. The vacuum anvil roll 82 is anexample of an upstream apparatus 82 that will transfer the article 10 atmatched tangential velocity to the vacuum head 80. Timing of vacuum tothe vacuum head 80 can be controlled by a vacuum manifold or a controlvalve. To provide enough space to rotate the vacuum heads 90 degrees andto begin adjusting vacuum head 80 spacing to the desired downstreampitch, the mover 24 is accelerated by the rack and pinion drives as themover 24 moves up to the timing belt drive 36. The timing belt drive 36engages with the mover 24 and carries the vacuum head 80 around theupper curved section 22B of the track. While the mover 24 is travelingthrough the curve, the rotational angle of the vacuum head 80 isadjusted 90 degrees. Axis of head 80 rotation is orthogonal to themachine direction path of the mover 24. Rotation of the vacuum head 80is optional and the apparatus could also repitch an article 10 withoutrotation or the apparatus could rotate the heads 80 only withoutrepitching. Head rotation can be accomplished using any of thefollowing: by interaction of a cam follower with a barrel cam; by camfollower interaction with a plate cam through a gear box as described inU.S. Pat. No. 8,720,666; by being driven by an electrical motor; orother means. When the mover 24 is transferred from timing belt 36 backto the pinion gear drive 32, the mover 24 and vacuum head 80 can beaccelerated by pinion drives 32 to adjust to the desired pitch spacingand surface speed required for transfer to the downstream process.Again, transfer of the component to the downstream vacuum transfer roll84 is at matched tangential velocity and is a controlled tangentialtransfer. The downstream vacuum transfer roll 84 is an example of adownstream apparatus 84. Vacuum applied to the vacuum head 80 can beshut off or transitioned to positive pressure at the region of transfer.This process is well controlled and lends itself to operate at very highspeeds. Because of the superior force and acceleration capability ofthis technology it is feasible to carry and accelerate the mass of aturning head and components at very high rates of speed compatible withdisposable product assembly machines. After component transfer, themover heads continue along the track and adjust pitch and head rotationto pick up the next component. An advantage of this embodiment versus amachine requiring a size specific cam such as U.S. Pat. No. 8,720,666 isthat the size of the product can be changed by adjusting the motionprofiles specified in software versus changing a cam or interchanging alarge piece of equipment. In fact, the turn and repitch embodimentdescribed herein is capable producing many different sizes of product bymaking a simple recipe change in the motion control software. Inaddition to discharging components at constant pitch and frequency, itis possible to adjust the deposition frequency electronically toactively change the discharge pitch or to deposit components on demandLikewise, it is possible to electronically control the timing foracquisition of components to pick up components of varying or uncertainpitch and to acquire on demand The head cover can be exchanged for asmaller head cover or the shape of the active vacuum area on the headcan be adjusted. This in combination with software adjustments furthercan enable different sizes of products. Clearly, an electronic turn andrepitch apparatus employing this principle can be reconfigured toaccomplish many tasks such as simply adjusting pitch only withoutturning or turning an angle other than 90 degrees. Adjustments to theprocess by software can enable instantaneous and even active adjustmentsto product format and sizes.

FIGS. 20-22 illustrate an exemplary discrete component assemblyapparatus with multiple assembly zones using the controlled motionsystem 20. FIGS. 20-22 are simplified schematic views that only show themovers 24. The racks, drive elements, and motors in FIGS. 20-22 are notshown for simplicity, but would be in the form shown and described inconjunction with the preceding figures herein.

FIG. 20 shows the continuous clockwise closed loop path P followed by aplurality of movers 24. Each mover 24 is configured to carry a carriertool 90 to carry an individual article 10. In this example, the article10 is a disposable razor cartridge, but it could be any discretecomponent or product. Likewise, each mover 24 could carry any number ofmultiple products or components. The top of the path P in this exampleis an active assembly zone and consists of decoupled indexing andcontinuously variable motion regions. The curves 22B and bottom of thepath P constitute a return path with controlled motion. Of course, suchan assembly machine could use the bottom portion of the path to completeassembly steps in addition to the top portion. Alternatively, the track22 could be oriented so that the straight sections are vertical whichcan further enable assembly steps on both straight sides of the track.Assembly steps can also be conducted in the curved regions of the track.

FIG. 21 illustrates an example of controlling the movers 24 to performdifferent index motions in the same track. Mover motion, MD, is fromleft to right. First, the movers 24 dwell to allow loading of twoplastic molded blade carriers 92. In this case, the molded bladecarriers 92 are components of a razor that are the payload for thecarrier tools 90. The carrier tools 90 may each have at least one cavity96 therein for receiving one, or more, of the molded blade carriers 92.After loading, two movers 24 rapidly index ahead two positions. Thisrapid double index enables a longer dwell for doing time dependentprocesses such as loading two blade carriers 92. Stopping more movers 24can allow even longer dwells and the high acceleration capability ofthis technology can allow rapidly indexing larger numbers of movers 24.This can allow stopping products produced at very high throughput andproviding long dwell times for time dependent processes such as heatsealing, stamping, embossing, etc. After the blade carriers 92 areloaded, next the movers 24 are each indexed once per product to alloweach of the four metal blades 94 to be inserted into the blade carriers92 in sequence during each dwell. All of these indexing motions can beperiodic and synchronous, or they can be asynchronous and triggeredbased on external random events.

FIG. 22 illustrates an example of controlling the movers 24 to performcontinuous and indexing motions in the same track. Mover 24 motion isfrom left to right. On the left, movers 24 are moving at a constantvelocity to enable inkjet printing onto the cartridge by an inkjetprinter 98. The print is registered to the position of the movers 24 byprecisely coordinating the motion. After printing, the movers 24 arestopped in groups of four to allow removal of four razor cartridges 100for placement in packaging. This index timing and pitch of the movers 24can be adjusted to create different size and spacing of groups forvarious packaging formats. For instance, the cartridges could be stopped2, 3, 4, 5, or 6 at a time to provide the required group size. Thistiming is easily software adjustable.

FIG. 23 illustrates another application of the controlled motion system20 to create groups of bottles 10 for a case packing application. U.S.Pat. No. 9,573,771 describes a system using individual movers to acquireand create software selectable groups of bottles. In U.S. Pat. No.9,573,771, the movers are each driven by individual servo driven timingbelts. FIG. 23 shows an alternative system in which each mover 24 can befitted with a rack and driven by a plurality of pinion gears and timingbelts as described herein. The racks, drive elements, and motors in FIG.23 are not shown for simplicity, but would be in the form shown anddescribed in conjunction with the preceding figures herein. Thisalternative system 20 would provide superior acceleration capability anddynamic performance Each mover 24 is provided with flights 104 that arespaced to transport bottles 10. The mover 24 can be indexed on demand tofill the mover 24 with four bottles 10 (or, in other configurations,with any other suitable number of bottles). The timing of bottles 10supplied to the movers 24 can be periodic, or the timing can be random.The random timing of bottles 10 can be sensed with an article positionsensor 102, and the mover 24 can respond to the random input sensed.Random timing of bottles 10 can be due to missing bottles 10 in aperiodic conveying stream or due to random placement of bottles 10 onthe conveyor. The movers 24 can then transport bottles 10 to theunloading region 106 where groups of movers 24 are coordinated toprovide the desired bottle count for unloading. The groups of bottles 10can be removed from the track 22 by a stripper tool 108, and then placedon another conveyor. Movers 24 can then return along path P to beloaded. Although this example is related to bottles 10, the principledisclosed could be reapplied to any desired articles 10.

The controlled motion system 20 is well suited for coupling andconveying articles 10 between upstream and downstream systems that arenot perfectly synchronized or not running at the same production rate(articles per minute). For instance, if an upstream apparatus thatnormally provides a periodic supply of articles 10 has a missing articledue to a reject, the controlled motion system 20 can provide a buffer oraccumulation to keep a non-interrupted supply of periodic articles to adownstream apparatus. If the upstream apparatus provides a non-uniformnon-constant production rate of articles 10, the controlled motionsystem 20 can provide a buffer and provide a constant periodic flow rateof articles to a downstream apparatus, or can smooth out rapid changesin instantaneous rate and provide more gradual changes to rate that thedownstream apparatus can adjust to. If a downstream apparatus mustmomentarily stop, the controlled motion system 20 can provide a bufferand allow the upstream apparatus to continue to run at normal rateuninterrupted. The controlled motion system 20 is also useful forconnecting apparatuses that start, stop, ramp up, or ramp down atdifferent rates. For instance if the downstream apparatus stops fasterthan the upstream apparatus, the controlled motion system 20 can storearticles produced by the upstream apparatus once the downstreamapparatus is stopped.

FIG. 24 illustrates another application of the controlled motion system20 that can be used to create dwell time for continuous motion, timedependent processes in a web substrate 110 moving in a linear machinedirection path. Time dependent processes include transformations andinterfaces such as embossing with heat, heat sealing, embossing withgradual strain of web material 110, stamping, punching, printing,thermoforming, curing, ultrasonic welding, bonding of multiplematerials, etc. Typically, tooling 112 and 114 is used to transform ormanipulate the web material 110 during dwell. The transformation orinterface of the tooling 112 with the web substrate 110 typically willhappen at a localized discrete region of the web substrate, and theselocalized regions are disposed in the machine direction at a constantpitch distance. The tooling can comprise pairs of matched tooling suchas 112 and 114, or the tooling can comprise a single tool that contactsor interfaces with the web 110. The web 110 can be continuous in themachine direction or can be discrete sheets or articles 10.

The embodiment in FIG. 24 includes two controlled motion systems 20A and20B, each with closed loop tracks 22. The drive elements and motors inFIG. 24 are not shown for simplicity, but would be in the form shown anddescribed in conjunction with the preceding figures herein. Thecontrolled motion systems 20A and 20 B are configured each with lineartrack sections 22A parallel to a web 110 running in continuous linearmotion. Controlled motion system 20A is positioned above the web 110 andcontrolled motion system 20B is positioned below the web 110. Thisexample illustrates heated embossing using matched male and femaleheated tooling 112 and 114, respectively. Other processes can use othertooling which can be matched between two controlled motion systems,articulated matched tooling transported by a single controlled motionsystem, and tooling that works from one side of a web that istransported by a single controlled motion system. For this exampleembodiment, each mover 24 on upper controlled motion system 20A isequipped with a female heated tool 114. Each mover 24 on lowercontrolled motion system 20B is equipped with a male heated tool 112that is matched to work with the heated female tool 114. In thisembodiment, the tooling is configured to emboss the letters “P&G” intothe web 110. Upper and lower movers 24 with corresponding female andmale tooling are transported at matched tangential velocity with the websubstrate 110. Motion for both upper and lower movers 24 and tooling iscoordinated such that the male and female tooling 112 and 114 isprecisely synchronized and registered with the position for embossmenton the web 110. As the male and female tooling 112 and 114 travel inclose proximity and at constant speed with the web 110, the male tooling112 is actuated to penetrate the web 110 and to push the web 110 intothe mating female tooling 114. Because both tools are traveling with theweb 110 in a straight line, the tooling can remain in contact with theweb 110 for an extended amount of dwell time. This can provide adequatetime to heat the web 110 and also cool the web 110 after embossment iscomplete. Once embossment is complete, the male tool 112 is withdrawnand the embossed web 110 can exit beyond the controlled motion systems20A and 20B.

Because the motion of each individual mover 24 is individuallycontrolled for position, velocity, acceleration, and jerk; it ispossible to use the controlled motion systems 20A and 20B to adjust themachine direction spacing of discrete features such as a heatedembossment for different size products on the fly by using a simplesoftware change to adjust the commanded pitch spacing between movers 24.When the pitch of the movers 24 in contact with the web 110 are changed,the relative position and accelerations of the movers 24 on the returnpath curves and straight away from the web 110 must be adjusted. Forinstance, if the pitch in contact with the web 110 is increased, themovers 24 are deaccelerated after contacting the web 110 to a smalleraverage pitch and smaller velocity until they are accelerated again tothe pitch and velocity needed to register with the web 110. It is alsopossible to achieve continuously variable pitch or position to allow themover 24 and tooling 112 and 114 to match a variable position in the web110 or to wait for a missing product such as with a reject.

FIG. 25 illustrates a closed path controlled motion system 20 created aswith a combination of sections driven by pinions 32 and timing belts 36.The motors are not shown for simplicity, but would be in the form shownand described in conjunction with the preceding figures herein. Sectionswhere relative motion between movers 24 is needed employ a plurality ofpinions 32. Sections where conveying is needed without relative motionbetween movers 24 employ timing belts 36. The cost per unit length forsections using timing belts 36 can be more affordable than sectionsusing a sequence of pinions 32. The controlled motion system 20 can alsobe scaled to any desired size and can be large enough to convey aproduct through an entire converting line or factory.

The controlled motion system 20 provides a high speed, high force,independent control of multiple movers (or cars) along a path, which maybe a closed track. This technology can be used to create higherperformance processes for numerous purposes including, but not limitedto: re-pitching, material transport, extended residence time, andautomated changeover.

The performance of the system described herein in comparison to priorsystems is described in the table below. The numbers in the table forthe Comparative Examples are from manufacturers' literature. The numbersin the table for the Controlled Motion System described herein are basedon calculations using motor torque from manufacturers' literature.

Comparison of Performance of Controlled Motion System to Prior SystemsPeak Thrust Continuous Maximum Force at Peak Thrust Thrust Force atContinuous Tangential Maximum Force at Zero Maximum Thrust Force atMotor Description Velocity (m/s) Velocity (N) Velocity (N) Velocity (N)Zero Velocity (N) Controlled Motion System Example Configuration 1 Using25.33 675 1272 314 534 Allen Bradley MPL-B580J-MJ74AA Rotary ServoMotors Coupled 1:1 with 20T CP20 127.325 mm Pitch Diameter Gear PinionsDriving Movers with CP20 Gear Racks Controlled Motion System ExampleConfiguration 2 Using 16.47 1039 1957 483 822 Allen BradleyMPL-B580J-MJ74AA Rotary Servo Motors Coupled 1:1 with 13T CP20 82.761 mmPitch Diameter Gear Pinions Driving Movers with CP20 Gear RacksControlled Motion System Example Configuration 3 Using 5.49 3117 58721450 2465 Allen Bradley MPL-B580J-MJ74AA Rotary Servo Motors Coupledwith a 3:1 planetary gear reducer to a 13T CP20 82.761 mm Pitch DiameterGear Pinions Driving Movers with CP20 Gear Racks Comparative Example 1:Rockwell Automation iTRAK 5 220 265 139 112 2198T-L16-T0504-A00N-2E1E-NSMotor Module with 2198T-MO515-A000 Mover Magnet per Bulletin Number2198T-TD001B-EN-P Comparative Example 2: Rockwell Automation iTRAK 2.7 0793 0 337 2198T-L16-T1504-A00N-2E1E-NS Motor Module with2198T-M1515-A000 Mover Magnet per Bulletin Number 2198T-TD001B-EN-PComparative Example 3: Beckhoff XTS AT2000-1000 4 80 100 30 30Comparative Example 4: Rockwell Automation 2.5 2.6 5.4 2.6 5.4MagneMotion MagneMover LITE ™ with Standard Puck

The term “joined to” as used throughout this disclosure, encompassesconfigurations in which an element is directly secured to anotherelement by affixing the element directly to the other element;configurations in which the element is indirectly secured to the otherelement by affixing the element to intermediate member(s) which in turnare affixed to the other element; and configurations in which oneelement is integral with another element, i.e., one element isessentially part of the other element.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

It should be understood that every maximum numerical limitation giventhroughout this specification includes every lower numerical limitation,as if such lower numerical limitations were expressly written herein.Every minimum numerical limitation given throughout this specificationwill include every higher numerical limitation, as if such highernumerical limitations were expressly written herein. Every numericalrange given throughout this specification will include every narrowernumerical range that falls within such broader numerical range, as ifsuch narrower numerical ranges were all expressly written herein.

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An apparatus for controlled motion of independentmovers along a path comprising a curved path comprising: a track thatforms a path for movers; wherein the path comprises at least one splinecurve section of non-constant radius; a first mover and a second movermovably mounted on the track for moving along the path, the moverscomprising a driven member that is oriented to be contacted by at leastone drive element at any position along the path; wherein the driveelement along the spline curve section of the path comprises a firstdrive belt and a second drive belt arranged around the track to followthe curvature of the spline curve section of the path; wherein thesecond drive belt is positioned downstream in a machine direction fromthe first drive belt, the drive belts each comprising a surface that isoriented to contact the driven member of the movers, wherein the drivebelts are configured to sequentially engage the driven member of themovers to provide controlled motion of the movers independently aroundthe track, wherein the drive belts are interleaved to provide continuouscontact with the driven member by at least one drive belt along theentire spline curve section of the path; wherein the drive belts areeach driven by a rotary motor; and a programmable computer controlsystem in communication with the rotary motors for controlling themotion of the rotary motors.
 2. The apparatus of claim 1, wherein thedrive belt is a toothed timing belt.
 3. The apparatus of claim 1,wherein the driven member is a gear rack.
 4. The apparatus of claim 0,wherein the toothed timing belt mechanically engages to drive the gearrack.
 5. The apparatus of claim 3, wherein the mover is mechanicallyengaged by the teeth of the timing belt.
 6. The apparatus of claim 1,wherein the drive belt at the curvature is supported by a plurality ofrollers, backing plates, or a combination of backing plates and rollers.7. The apparatus of claim 5, wherein the drive belt at the curvature issupported by a backing plate comprising a low friction material.
 8. Theapparatus of claim 5, wherein the drive belt at the curvature issupported by a backing plate comprising small orifices adapted forcompressed air to flow through to float the drive belt across thebacking plate.
 9. The apparatus of claim 1, wherein of the first moverand the second mover are independent movers mounted on the track andadapted for moving along the path wherein the movers are capable ofchanging velocity, acceleration, and/or relative position by engagementwith the drive belts.
 10. The apparatus of claim 1, wherein the firstand second drive belts are interleaved with a trailing region of thefirst drive belt overlapping a leading region of the second drive belt.11. The apparatus of claim 10, wherein the motion of the first andsecond drive belts can be synchronized so that the driven member for thefirst or second mover smoothly transitions between the belts.
 12. Theapparatus of claim 1, wherein the path further comprises a straightsection.
 13. The apparatus of claim 12, wherein a third drive belt isarranged around the track to follow the straight section of the path andconfigured to drive the driven member of the first or second moverthrough the straight section of the path.
 14. The apparatus of claim 1,wherein the driven member for the first mover and the first drive beltare positioned in a first lane; wherein the driven member for the secondmover and the second drive belt are positioned in a second lane that isparallel to the first lane; wherein the driven members in the first andsecond lane are adapted to move independently at varying relativeposition, velocity, and/or acceleration.
 15. The apparatus of claim 14,wherein the first and second driven members in the first and second laneare in close proximity in the machine direction.
 16. The apparatus ofclaim 15, wherein the first and second driven members in the first andsecond lane overlap in the machine direction.
 17. An apparatus forcontrolled motion of independent movers along a path comprising: a. aclosed loop track comprising: i. a straight section; and ii. a splinecurve section; wherein the track forms a path for movers; b. a firstmover comprising a first driven member that is oriented to travel in thepath and to be contacted by at least one drive element at any positionalong the path; wherein the first driven member comprises a first gearrack joined to the first mover; c. a second mover comprising a firstdriven member that is oriented to travel in the path and to be contactedby at least one drive element at any position along the path; whereinthe second driven member comprises a first gear rack joined to thesecond mover; d. a first drive element comprising a first drive belthaving a back side; wherein the first drive belt is configured to followthe curvature of the spline curve along a first portion of the curvedsection of track; and the first drive belt transports either the firstor second mover around the first portion the curved section of track;wherein portions of the first belt along the spline curve are supportedby a plurality of backup rollers and/or backing plates; wherein thefirst drive belt is a first toothed timing belt; wherein the firsttoothed timing belt mechanically engages and drives the first or secondgear rack. e. a second drive element comprising a second drive belthaving a back side; wherein the second drive belt is configured tofollow the curvature of the spline curve along a second portion of thecurved section of track; and the second drive belt transports either thefirst or second mover around second portion the curved section of track;wherein portions of the second belt along the spline curve are supportedby a plurality of backup rollers and/or backing plates; wherein thesecond drive belt is a first toothed timing belt; wherein the secondtoothed timing belt mechanically engages and drives the first or secondgear rack.
 18. The apparatus of claim 17, wherein portions of the drivebelt are supported by one or more backing plates comprising a lowfriction material.
 19. The apparatus of claim 9, wherein the drive beltat the curvature is supported by a backing plate comprising smallorifices adapted for compressed air to flow through to float the drivebelt across the backing plate.